HUSABERG ENDURO FE 400 User manual

INDEX
1
1
2
3
4
5
6
7
8
9
11
10
12
SAFETY AND PRECAUTIONS Page 4-
GENERAL INFORMATION Page 6-
MAINTENANCE SCHEDULE Page 9-
CONTROLS Page 12-
WIRING DIAGRAMS Page 31-
INTRODUCTION Page 2-
STARTING PROCEDURE Page 15
ENGINE Page 16- A LUBRICATION SYSTEM
B IGNITION
C AIR FILTER
D VALVE ADJUSTMENT
WHEELS & BRAKES Page 23- A WHEELS
B CHAIN
C BRAKES
SUSPENSION Page 28- A SUSPENSION
B STEERING HEAD
C SWINGARM
FUEL & COOLING Page 20- A CARBURETTOR
B FUEL
C COOLING SYSTEM
CLUTCH & DECOMPRESSION Page 22

INTRODUCTION
2
11Please read and observe the following:
Warning
If the engine has to be running during any maintenance, make sure that the area is
properly ventilated. Never run the engine in a closed area though the exhaust fumes
are posionous and thus hazardous to your health and life.
Warning
Althoughthebatteryisofasealedconstruction, please takecare.Theelectrolytecontains
sulfuric acid and you must protect your eyes, skin and clothing if such fluid is assumed
to be leaking or likewise exposed. In case of contact, wash and flush thoroughly with
water and contact medical help if needed, especially if your eyes have been exposed to
the fluid.
Warning
Fuel is extremely flammable and explosive under certain conditions. Do not smoke or
expose the fuel to open fire or sparks.
SERVICE CONDITIONS:
1. Always use original Husaberg parts.
2. Use the special Husaberg tools when required.
3. Install new gaskets, o-rings, circlips etc whenever possible.
4. Always clean all parts thoroughly before assembly.
5. All screws, nuts and bolts etc. are in the metric system. Do not use incorrect tools.
Endurovägen, S-695 72 SWEDEN
www.husaberg.se
f[email protected]
PRINT & COPY RIGHTS
Thematerial andinformation includedinthisOwner’sManualare all ofthelatest editions
available at the time of the printing.
Husaberg Motor AB reserves the right to make changes regarding the products at any
time without prior notice.
This Owner’s Manual is subject to corrections without prior notice.
No part of this Owner’s Manual may be reproduced without written permission

INTRODUCTION
3
1
1
Always put the motorcycle on a stable centerstand
whenever removing either front or rear wheel.
ATTENTION:
Never ride your motorcycle under the influence of
alcohol,drugs,barbiturates or any other kind of medical
treatments hazardous to your riding performance.
ATTENTION:
Never ride in a too low or too high gear -
Neverlettheenginerunformorethanoneminutewhilestationary
It may cause severe mechanical damages
ATTENTION:
ATTENTION:
Service more frequently when
riding under hard conditions
ATTENTION:
Do not use a highpressure jet-cleaning
equipment on surfaces around
bearingsand other fragile components.
WARNING:
Do not check the coolant
level while the engine is hot.
ATTENTION:
Less clearances than the required
cause severe engine damages
Dear client,
We feel ourselves privileged and honoured to be the supplier of your choice of motorcycle.We
know for sure that our product will give you years of fun and performance though the Husabergs
are based upon decades of experience in racing and a dedication hard to find elsewere.You’re
bound to feel this through the inborn lively spirit of your bike.
Although mainly designed and constructed for competition purposes it is still very rider-friendly
but due to the design the product needs careful and proper maintenannce. In order to get the
most out of your "beast" and before any use of the motorbike; we highly recommend you to
carefully read this Owner's Manual through. We also recommend you to pay your outmost
attention to the following page regarding safety and precautions and always remember the
fundamental base of all activities on two wheels:
- "Do not overestimate your capabilities, follow the domestic regulations and do think about
your surroundings"
Although the Owner's Manual is put together and written in a way that will make it possible for
an average mechanical experienced person to take care of the maintenance, we recommend
you to let an authorized Husaberg dealer take care of at least the parts we’ve mentioned under:
Also, part of the maintenance has to be performed by an authorized dealer in order to fulfill the
terms of warranty.
If you follow the advice regarding the set-up and of course also regarding the vital maintenance
of the motorcycle; the Husaberg of yours will provide a maintained level of performance (read:
joy and satisfaction - the reason to your choice of brand).
The personnel of Husaberg Motor AB Sweden

SAFETY AND PRECAUTIONS
4
2
2
Never ride your motorcycle under the influence of
alcohol,drugs,barbiturates or any other kind of medical
treatments hazardous to your riding performance.
ATTENTION:
SAFETY
PROTECTION:
Always protect yourself with adequat clothing and protective apparel.
Always wear a helmet, goggles and boots.
MOTORCYCLE:
The motorcycle may become dangerous to ride if it is modified or if any other parts than
originalHusabergpartsareused.The use ofotherparts than originalmakesthewarranty
no longer valid.
Always keep your motorcycle in a safe state and in the best of conditions.
Regular cleaning and maintenance are extremely vital in order to avoid any mechanical
damages hazardous to you and/or your surroundings.
TRANSPORTATION:
Always transport your bike upright in order to avoid any leakages of oil and/or fuel.
Such fluids may increase the risk of fire. Always make sure that the bike is properly
fastened in a safe and firm position during transportation.
RIDING:
Always check the motorcycle for any deterioration/damages and any necessary
adjustments before you start the motorcycle (see "Pre-ride inspection").
Though the Husaberg motorcycle has a very high level of performance; always ride
with care and do not overestimate your capabilities. Get to know your Husaberg
motorcycle really well before you try to get the most out of it.
Never lend your motorcycle to any other rider unless you are sure that he/she is fully
capable of handling it.
Always obey all local and federal regulations and laws valid within the territory.
Never ride in terrain unfamiliar to you unless inspected and guaranteed by the local
authorities.
PRE-RIDE INSPECTION:
Make it a habit to give your motorcycle an inspection before and after every ride.
Always check all bolts and nuts and tighten if necessary - All for your own safety.
A clean and well lubricated bike makes for a safer ride as well as a higher value of the
machine. The Pre-ride Inspection Checklist on the next page is to be regarded as a
brief summary of the main important items to be controlled and, if necessary; to be
adjusted or replaced.

SAFETY AND PRECAUTIONS
5
2
2PRE-RIDE INSPECTION CHECK LIST
Engine oil Check the level and fill up if necessary.
Check for any leakages in the casing.
Ignition Check the sparkplug cap/HV lead for damages.
Radiator Check the coolant level and fill up if necessary.
Checkfor leakages and/ordamages of thecellsand hoses
and attachments.
Airfilter Clean, or if necessary, replace the filter
Carburettor Check the function of the throttle/cable and adjust/replace
any damaged parts if necessary.
Adjust the idling- and/or mixture screw if necessary.
Clutch Check the function and for any leakages.
Decompression Check the function of the manual and the semi-automatic
decompressionleverandadjustifnecessary (non-electrical
starter models only).
Chain Check and adjust/replace the chain if necessary.
Check the sprockets and replace if necessary.
Suspension Checktheoperationofthefrontforkandtheshockabsorber
and adjust if necessary.
Check and tighten the swingarm if necessary.
Wheels Check the air pressure of the tyres and fill up if necessary.
Check the spokes and tighten if necessary.
Brakes Check the level of brakefluid and fill up if necessary.
Check for any leakages and the function of the brakes.
Adjust levers and/or replace hoses/pads if necessary.
Fuel Check the level and fill up if necessary.
Check for any leakages in the fuel lines.
Steering Check the clearance of the steering head bearings and
adjust if necessary.
Controls Check the function of the speedometer or odometer (if
incl.in equipment).
Lighting Check the functions of the front-, tail-, and brake lights
(and any occuring turn signals).

GENERAL INFORMATION
6
3
3SPECIFICATIONS
ENDURO MOTOCROSS ELDURO DESERT (FX)
Liquid cooled, 4-stroke single cylinder, SOHC-4 valves
400-models:399cc / Bore 92,0 mm x Stroke 60,1 mm
501-models:501cc / Bore 95,0 mm x Stroke 70,7 mm
600-models:595cc / Bore 95,0 mm x Stroke 84,0 mm
400-models:12,0:1
501-models:11,8:1
600-models:11,6:1
One automatic system activated by the
camshaft, oneactivatedbythekickstarter
and one operated by a manual lever
Fully automatic system activated by
the camshaft plus one operated by a
manual lever
Kick starter Electrical- and kick starter
2 mm ± 1 mm 2 mm ± 1 mm
Intake and Exhaust:0,10 mm
SUBJECT/MODEL
Engine type
Displacements
Compression ratio
Decompression system
Start system
Decomp.cable clearance
Valve clearance Orbit oilpump and reedvalve controlled lubrication
Oil-cooled piston and connecting rod
Replaceable micro filter and washable oil screen
1,0 Litre Synthetic SAE 5W-50 API SG/CF (minimum SAE 15W-50)
SEM, CDI, DFC™;Dynamic Force Control
Lubrication
Engine oil
Ignition NGK DCPR8E / 0,7 mmSpark plug / gap 1,3 litre of 50% Anti-freeze, with corrosion inhibitor, and 50% waterCoolant 12V / 70 + 70 W Not available 12 V / 70 + 70W 12 V / 70 + 70 WAlternator
Inox steel pipes, 2 into 1 collector, Aluminium/Inox silencer (FCTitanium/Inox)
US-versions except FC models equipped with spark arrester
Exhaust system
Fuel capacity All models except FR 600 E:9 litres
FR 600 E: 25 litres
520 O-ring chain
15/42 - 2,800
15/42 - 2,800
13/48 - 3,692 13/48 - 3,692 13/48 - 3,692
15/48 - 3,200 (15/48 - 3,200) 15/48 - 3,200 15/48 - 3,200
15/48 - 3,200 (15/42 - 2,800) 15/48 - 3,200 15/48 - 3,200
400-models:Dellorto PHM 38
501- & 600-models:Dellorto PHM 40
Dual Sport USA - FS 600:Edelbrock Qwiksilver 38
All models except FR 600 E:Single foam filter
FR 600 E:Double foam filters
RON 98 (octane), unleaded
29/78 - 2,690
Spur gears
Clutch hydraulic oil
Secondary transmission
Ratios 501/4-speed
600/4-speed
400/6-speed
501/6-speed
600/6-speed
Carburettor
(std. jetting see page 8)
Air filtration
Fuel
Ratio
Primary transmission
Hydraulic, 7 friction- and 8 mating plates in oil bathClutch
Gearbox
Ratios 1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Mineral oil SAE 2-7W
6-speedWR 4 or (6)-speed CR 6-speedWR 6-speed S-WR
15/32 - 2,133 13/34 - 2,615 15/32 - 2,133
*17/30 - 1,765 18/28 - 1,555 17/30 - 1,765 18/28 - 1,555
*20/27 - 1,350 20/25 - 1,250 20/27 - 1,350 20/25 - 1,250
*23/24 - 1,043 23/24 - 1,043 23/24 - 1,043 23/24 - 1,043
25/22 - 0,880 (24/22 - 0,917) 25/22 - 0,880 25/22 - 0,880
*FC 4-speed WR
*13/34 - 2,615
(25/21 - 0,840) 27/20 - 0,741 27/20 - 0,741 27/20 - 0,741

GENERAL INFORMATION
7
3
3
SPECIFICATIONS
1490 mm
1490 mm
930 mm
900 mm
380 mm
350 mm
810 mm
810 mm
2200 mm
2150 mm
Wheelbase
Wheelbase Super M.
Seat height
Seatheight Super M.
Groundclearance
Groundclearance SuperM.
Overall width
Overall width Super M.
Overall length
Overall length Super M.
Weight (dry) kg:
400/6-speed
501/4-speed
501/6-speed
600/4-speed
600/6-speed
Super Motard + 2,5 kg
Front fork oil
Front fork oil capacity
Brake fluid
Lubrication of bearings
Wear limit brake pads
Wear limit clutch discs
Drive chain
Wear limit drive chain
12V 65/50 W - P43t
12V 45/40 W - BA20d
12V 21/5 W - BAY15d
12 V 4W - BA9s
12V 10 W - BA15s
12 V 2W - BA7s
Not applicable
Headlight
HeadlightUS-models
Tail- / Stop light
Parking light
Turn signal light
Speedometerlight
Battery
Main fuse
ENDURO ELDURO MOTOCROSS DESERT (FX)
Heat-treated (DIN) 25CrMo4 steel
SUBJECT/MODEL
Frame 28,5°Caster Hydraulic front fork ø 43 mm / 280 mm
WP MXMA 4358 HUSABERG-E
Progressive Damping System - PDS
WP 5018 HUSABERG-E 320 mm
Hydraulic front fork ø 43 mm / 280 mm
WP MXMA 4358 HUSABERG-MX
Progressive Damping System - PDS
WP 5018 HUSABERG-MX 320 mm
Front suspension
Rear suspension
BREMBO, hydraulic, twin piston (Super Motard four piston) floating caliper
ø 260 mm (Super Motard ø 320 mm) stainless steel brake disc
BREMBO, hydraulic, single piston floating caliper
ø 220 mm stainless steel brake disc
Front brake
Rear brake
Tyre pressure (cold)
Front
Front Super M.
Rear
Rear Super M.
Front rim/tyre
Front rim/tyre Super M.
Rear rim/tyre
Rear rim/tyre Super M.
Not applicable 12 V 8 Ah
15 A Not applicable 12 V 8 Ah 15 A
104,8
105,2
105,7
112,4
112,5
112,9
102,0
102,4
102,4
102,9
112,0
112,4
FR 600 E: 118,9
WP SAE 5
According to WP Manual
DOT 4
Molybdenum sulphide grease
1,5 mm
19,6 mm
D.I.D.O-ring
272 mm - 18 chain reels (tensioned, center distance between reels)
EXCEL1.60x21”/90/90-21”
EXCEL2.15x18”/130/80-18” 2.15x19”/130/70-19” 2.15x18”/130/80-18”
Not applicableBEHR3.50X17”/120/70-17”
Not applicableBEHR4.25x17”/160/60-17”
Offroad use: 0,8 bar (12,0 psi) / Street Use: 1,0 bar (14,5 psi)
Offroad use: 0,8 bar (12,0 psi) / Street Use: 1,0 bar (14,5 psi)
Not applicable2,2 bar (31,9 psi)
Not applicable2,0 bar (29,0 psi)

GENERAL INFORMATION
8
3
3
1. Flywheel puller - Article No. 270028-01
2. Flywheel holder - Article No. 270030-01
Tool kit - Article No. 390029-01
CARBURETTOR STD. JETTINGS
MODEL/SUBJECT
(Exploded view number)
Main
jet
# 6
Needle
jet
# 4
Needle
# 3
Needle
clippos.
# 26
Pilot
jet
# 7
Throttle
# 2
Float
valve
# 9
Mixture
screw
# 33
Start
jet
# 8
ENDURO FE 400 190 DR 270 K 35 #3 35 40 300
FE 501 190 DR 270 K 51 #3 33 40 300
FE 600 195 DR 270 K 35 #3 48 50 300
ENDURO ECE FE 400 110 DR 266 K 51 #2 48 70 300
FE 501 110 DR 264 K 35 #4 33 70 300
FE 600 110 DR 268 K 51 #3 42 70 300
ENDURO USA FE 400 190 DR 270 K 35 #3 35 40 300
FE 501 190 DR 270 K 35 #3 33 40 300
FE 600 195 DR 270 K 51 #3 33 40 300
ELDURO FE 400 E 190 DR 270 K 35 #3 35 40 300
FE 501 E 190 DR 270 K 51 #3 33 40 300
FE 600 E 195 DR 272 K 51 #3 48 50 300
ELDURO ECE FE 400 E 110 DR 266 K 51 #2 48 70 300
FE 501 E 110 DR 264 K 35 #4 33 70 300
FE 600 E 110 DR 268 K 51 #3 42 70 300
ELDURO USA FE 400 E 190 DR 270 K 35 #3 35 40 300
FE 501 E 190 DR 270 K 35 #3 33 40 300
FE 600 E 195 DR 270 K 51 #3 33 40 300
MOTOCROSS FC 501 190 DR 270 K 35 #3 33 40 300
FC 600 195 DR 272 K 51 #3 33 40 300
DESERT USA FX 501 E 190 DR 270 K 35 #3 33 40 300
FX 600 E 195 DR 270 K 51 #3 33 40 300
RALLYE FR 600 E 195 DR272 K 51 #3 48 50 300
RALLYE USA FR 600 E 195 DR 270 K 51 #3 33 40 300
DUAL SPORT FS 600 E - - K 6 19 out - - -
2 turns
1½turns
1½turns
1¼turns
1 turn
1½turns
2turns
1½turns
1½turns
2turns
1½turns
1½turns
1¼turns
1 turn
1½turns
2turns
1½turns
1½turns
1½turns
1½turns
1½turns
1½turns
1½turns
1½turns
-
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
45
-

GENERAL INFORMATION
9
3
3
4MAINTENANCE SCHEDULE
C: Clean - I: Inspect - R: Replace - *Maximum 12 months interval
Chassis - Enduro and Elduro models
Chassis - Motocross and Desert models
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
55
5
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*liokroftnorF RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
*diulfekarB RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
sgnihsub/sgniraebmragniwS II
I
II II
I
II II
I
II II
I
II
sgnihsubrebrosbakcohS II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
sgniraebdaehgnireetS II
I
II II
I
II II
I
II II
I
II
sgniraebleehW II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
010101010102020202020303030303040404040405050505050606060606070707070708080808080909090909001001 001 001001011011 011 011011021021 021 021021031031 031 031031041041 041 041041051051 051 051051061061 061 061061071071 071 071071081081 081 081081091091 091 091091002002 002 002002
*liokroftnorF RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
*diulfekarB RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
sgnihsub/sgniraebmragniwS II
I
II II
I
II II
I
II II
I
II
sgnihsubrebrosbakcohS II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
sgniraebdaehgnireetS II
I
II II
I
II II
I
II II
I
II
sgniraebleehW II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
TORQUE VALUES
5 NmOil filter cover screws 5 Nm Apply a threadlock liquidReed valve screws 5 NmValve inspection cover screws 5 Nm
Waterpump cover screws
SUBJECT TORQUE NOTE
5 NmIntake manifold screws
Standard torque values M8 M10
25 Nm 40 Nm M12 40 Nm M16 125 Nm
10 NmCrankcase screws 8 NmStator screws
10 Nm
Exhaust pipe screws 10 NmGearshift lever screw 10 Nm Apply a threadlock liquidKick start lever screw 10 NmTransmission cover screws 10 NmValve cover screws 12 Nm
Oil drain plug
10 Nm
Cylinder head (M6) screws
12 NmValve adjustment lock nuts 12 Nm
Spark plug
25 Nm Apply a threadlock liquidUpper timing sprocket screws 44 NmCylinderstud nuts 50 Nm Left-handthreadFlywheel nut 80 NmPrimary gear wheel nut
15 NmFront fork triple clamp screws (M8)
125 NmSwingarm shaft nuts M6
10 Nm
M5
8 Nm
M4
6 Nm

MAINTENANCE SCHEDULE
10
4
4
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
55
5
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RALUGERRALUGER RALUGER RALUGERRALUGER
lioenignE RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
neercsliO CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC
retliforcimliO RR
R
RR RR
R
RR RR
R
RR RR
R
RR
evlavdeer.lcnipmupliO C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
*diuqiltnalooC RR
R
RR
)pac.lcni(gulpkrapS II
I
II RR
R
RR II
I
II RR
R
RR
**noitingI/rotanretlA II
I
II II
I
II
ecnaraelcevlaV II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
sgnilaes&sediug.lcnisevlaV II
I
II
renoisnet.lcniniahcgnimiT II
I
II
nip&sgnir.lcninotsiP II
I
II
rednilyC II
I
II
dorgnitcennoC II
I
II
niptfahsknarC II
I
II
scsid.lcnimsinahcemhctulC II
I
II II
I
II
***rotterubraC C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
pmupleufmgarhpaiD C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
msinahcemtratskciK II
I
II
msinahcemtfihsraeG II
I
II
msinahcemleehweerF:LE II
I
II
SGNIRAEBSGNIRAEB SGNIRAEB SGNIRAEBSGNIRAEB
dorgnitcennoC RR
R
RR
tfahsknarC II
I
II
tfahsniamxobraeG II
I
II
tfahsyradnocesxobraeG II
I
II
murdtfihS II
I
II
tfahsmaC II
I
II
etalperusserphctulC II
I
II
msinahcemtratskciK II
I
II
leehwraegetaidemretnI II
I
II
tfahsetaidemretnI:LE II
I
II
recnalabretnuoC:LE II
I
II
SGNIHSUBSGNIHSUB SGNIHSUB SGNIHSUBSGNIHSUB
dorgnitcennoC RR
R
RR
smrarekcoR II
I
II
tfahstratskciK II
I
II
tfahshctulC II
I
II
Engine - Motocross and Desert models
Please observe: Riding under hard conditions demands more frequent maintenance
C: Clean - I: Inspect - R: Replace
* Maximum 12 months interval - ** Clean whenever the engine has been washed - *** I(R):Especially needle and needle jet

MAINTENANCE SCHEDULE
11
4
4
SRUOH/TCEJBUSSRUOH/TCEJBUS SRUOH/TCEJBUS SRUOH/TCEJBUSSRUOH/TCEJBUS
010101010102020202020303030303040404040405050505050606060606070707070708080808080909090909001001 001 001001011011 011 011011021021 021 021021031031 031 031031041041 041 041041051051 051 051051061061 061 061061071071 071 071071081081 081 081081091091 091 091091002002 002 002002
RALUGERRALUGER RALUGER RALUGERRALUGER
lioenignE RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR RR
R
RR
neercsliO CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC CC
C
CC
retliforcimliO RR
R
RR RR
R
RR RR
R
RR RR
R
RR
evlavdeer.lcnipmupliO C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
*diuqiltnalooC RR
R
RR
)pac.lcni(gulpkrapS II
I
II RR
R
RR II
I
II RR
R
RR
**noitingI/rotanretlA II
I
II II
I
II
ecnaraelcevlaV II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II II
I
II
sgnilaes&sediug.lcnisevlaV II
I
II
renoisnet.lcniniahcgnimiT II
I
II
nip&sgnir.lcninotsiP II
I
II
rednilyC II
I
II
dorgnitcennoC II
I
II
niptfahsknarC II
I
II
scsid.lcnimsinahcemhctulC II
I
II II
I
II
***rotterubraC C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
pmupleufmgarhpaiD C/IC/I C/I C/IC/I C/IC/I C/I C/IC/I
msinahcemtratskciK II
I
II
msinahcemtfihsraeG II
I
II
msinahcemleehweerF:LE II
I
II
SGNIRAEBSGNIRAEB SGNIRAEB SGNIRAEBSGNIRAEB
dorgnitcennoC RR
R
RR
tfahsknarC II
I
II
tfahsniamxobraeG II
I
II
tfahsyradnocesxobraeG II
I
II
murdtfihS II
I
II
tfahsmaC II
I
II
etalperusserphctulC II
I
II
msinahcemtratskciK II
I
II
leehwraegetaidemretnI II
I
II
tfahsetaidemretnI:LE II
I
II
recnalabretnuoC:LE II
I
II
SGNIHSUBSGNIHSUB SGNIHSUB SGNIHSUBSGNIHSUB
dorgnitcennoC RR
R
RR
smrarekcoR II
I
II
tfahstratskciK II
I
II
tfahshctulC II
I
II
Engine - Enduro and Elduro models
Please observe: Riding under hard conditions demands more frequent maintenance
C: Clean - I: Inspect - R: Replace
* Maximum 12 months interval - ** Clean whenever the engine has been washed - *** I(R):Especially needle and needle jet

CONTROLS
12
5
5
IDENTIFACTION NUMBERS
The Vehicle Identification Number is placed on
the right side of the steering head (Fig.5A-1).
TheEngineNumberisplaced on the rightsideof
the engine, just below the cylinder (Fig.5B-1).
STEERING LOCK
The lock (if incl.in equipment) is placed on the
right side of the steering head (Fig. 5A-2).
We recommend you to follow the conditions of
your insurance regarding the use of anti-theft
devices.
IGNITION LOCK
Theignition lock(allElduro-models exceptsome
US-models) is either placed to the right of any
speedometer(Fig.5C-1)orinaseparatbracket.
The first position, maximum counter-clockwise,
meansthatthebikecannotbe started.Nolights
in function.
The second position, clockwise, means that the
bike can be started with the kick starter but not
with the electrical starter. Available lights in
function.
Thethirdposition,clockwise,meansthatthebike
can be started with both the kick starter and the
electrical starter. Available lights in function.
Fig.
5A
Fig.
5B
Fig.
5C
Fig.
5D
IGNITION SWITCH
Theignitionswitch (onlysomeelectricalstarter
US-models) is placed on the right side of the
battery box (Fig. 5D-1).
The bottom position of the knob; the bike can
not be started with the electrical starter but still
with the kick starter. Battery is disconnected
from the system. Available lights in function if
the motor is running.
The outer position of the knob; the battery is
connected. Electrical starter in function and
available lights in function.

CONTROLS
13
5
5
Fig. 5E Combination switch Type I:
1- Headlight switch
(Parking - Off - Low - High beam)
2- Turn signal switch
3- Horn button
4- Engine shortcircuit button
5- Clutch lever adjustment
6- Clutch lever
7- Manual dekompression lever
Fig. 5F Combination switch Type II:
1- Headlight switch
(Off - Low - High beam)
2- Horn button
3- Engine shortcircuit button
Fig. 5G 1- Engine shortcircuit button
(Motocross models)
2- 2-step ignition switch
Low - Normal conditions
High - Starts and heavy tracks
Fig. 5H 1- Light switch
(On - Off, Enduro-US models)
Fig.
5E
Fig.
5F
Fig.
5G
Fig.
5H

CONTROLS
14
5
5
Fig. 7A
OFF ON
Fig.
5I
Fig.
5J
Fig.
5K
Fig.
5L
Fig 5I 1- Twistgrip
(Electrical starter models)
2- Electrical starter button
3- Engine shortcircuit switch
Fig. 5L 1- Speedometer
(If incl. in equipment)
2- Highbeam indicator lamp
3- Turn signal indicator lamp
4- Trip meter knob
Fig. 5K 1- Twistgrip
(Non-electrical starter models)
2- Frontbrake lever
3- Frontbrake fluid reservoir

STARTING PROCEDURE
15
6
Never ride in a too low or too high gear -
Neverlettheenginerunformorethanoneminutewhilestationary
It may cause severe mechanical damages
ATTENTION:
ON OFF
RESERVE
6
Kick starter models:
Follow the checklist on page 5.
Turn the fuel tap/taps (Fig.6A-1) to position ON
(Fig. 6B-1).
Cold engine:Turn the choke lever (Fig 6A-2) to
position ON (Fig.6B-2) by pulling it downwards
and twisting it 90°.
Warm engine: Choke lever should be in OFF
position.
Put the gearshift lever into neutral.
Withthethrottlefullyclosed, makeadistinctand
longkickallthewaythroughtheoperationalorbit
ofthe kickstart lever.Iftheenginedoesnotstart,
let the kick start lever return all the way back in
order to provide the maximum distance for the
kick start lever and also activating the additional
semi-automatic decompression system.
Cold engine:Warm the engine up (the throttle a
little bit opened) with the choke on until it runs
smoothly.
Engine idling, pull the clutch lever fully towards
the handlebar and engage the 1st gear by
pushingthegearshiftleverdownwards.Openthe
throttle slightly at the same time as you slowly
and gently release the clutch lever.
Shift the gears as soon as adequate rpms have
been achieved.
Electrical starter models:
Follow the checklist on page 5.
Turn the fuel tap/taps (Fig.6A-1) to position ON
(Fig. 6B-1).
Cold engine:Turn the choke lever (Fig 6A-2) to
position ON (Fig.6B-2) by pulling it downwards
and twisting it 90°.
Warm engine: Choke lever should be in OFF
position.
Put the gearshift lever into neutral.
With the throttle fully closed, push the electrical
start button.
Cold engine:Warm the engine up (the throttle a
little bit opened) with the choke on until it runs
smoothly.
Engine idling, pull the clutch lever fully towards
the handlebar and engage the 1st gear by
pushing the gearshift lever downwards.
Open the throttle slightly at the same time as
you slowly and gently release the clutch lever.
Shift the gears as soon as adequate rpms have
been achieved.
The electrical start models are all equipped with
kickstarters.Followtheinstructionsabove:”Kick
starter models”, if used. Note that although no
additional semi-automatic decompression
systemisinstalledin an electricalstarterengine
thekickstarterleverhastobeusedasdescribed.
Fig.
6A
Fig.
6B
Fig.
6C

ENGINE
16
7
ATTENTION:
Take care - the oil could be very hot
ATTENTION:
Service more frequently when
riding under hard conditions
OIL LEVEL
Oilandfilterchangeandcleaningofoilscreen:
The oil is preferably changed while the engine
is warm.
Drain the oil by removing the oil drain plug (Fig.
7A-1,wrenchNo.13)andtheattachedoilscreen.
Remove the cover of the microfilter by removing
the ignition cable clamp (Fig.7A-2, allen key No.
5) and the two allen screws (Fig.7A-3, allen key
No. 4) and pull out the cover and filter by using
one M 6 screw as a puller into the center of the
cover.
Lubricate the surface of the cover's O-rings and
theO-ringof thenewmicrofilter(Fig.7B-2, 7B-3).
Insert the microfilter in reverse order of
disassembly.
Refit the oil drain plug and the attached, well
cleaned, oil screen.
Refill the engine with the adequate amount of oil;
1,0litre,throughthefiller hole(Fig.7C-1).Correct
level of oil as shown (Fig.7D)
Whenever checking the oil level the motorcycle/
engine has to be in an upright position.
LUBRICATION SYSTEM:
Always use a synthetic oil of a well-known
brand, viscosity SAE 5W-50.
Depending on the basic design of the engine;
competition purposes = equal to a small sized
engine thus giving a small capacity of oil, it is
vital that the oil is frequently changed.
Packedintothe crateofatotallynewmotorcycle
is an additional microfilter.The filter installed in
the engine, and the engine oil, has to be
changed after the first two hours of operation.
Thewashableoilscreenhas to befullycleaned
at the same time.
After the first change of oil and filter, incl.
cleaning of the oil screen, the intervals are
maximum 5 hours (motocross and desert
models)or 10hours(allothermodels)regarding
change of oil and cleaning of the screen and
every 25/50 hours regarding exchange of the
microfilter.
After every 100 hours the reed valve of the
lubication system has to be inspected and
cleaned.
7 A
Fig.
7A
Fig.
7B
Fig.
7C
Fig.
7D

ENGINE
17
7
Fig.
7E
Fig.
7F
Fig.
7G
Fig.
7H
7 B
IGNITION:
TheignitionsystemisaCDI-systemwithout any
contact-breaker to change or any other moving
parts apart from the flywheel. However, the
system has to be frequently checked and
cleaned for a maximum of durability and
performance.
The inside of the ignition cover, the stator, the
flywheel and the surroundings are preferably
cleaned after every time the motorcycle has
beenusedand/or washed(cover removal;three
allen screws, allen key No.5). Due to the heat
of the engine a condensation is built up around
the stator and flywheel which could cause the
system to work improperly. Check the surface
of the cover for any damages in order to avoid
any leakages.
Frequently check the spark plug (Fig.7E-1) for
wear and the colour of the electrode coating
(spark plugwrench,article No.270007-01).The
colour ought to be pale brown. A dark or black
colour means that the carburettor's setting is
on the rich side and a light or white colour
means that it is too lean (see "FUEL &
COOLING-CARBURETTOR”).Checkalso the
The correct electrode gap is 0,7mm.
Recommended spark plug is NGK DCPR8E.
Tightening torque 12 Nm.
Ignition timing:
Remove the inspection cover (Fig.7F-1).
Put the engine inTDC position (see ”ENGINE -
VALVE ADJUSTMENT”).
The ignition is propely set if:
400cc- & 501cc- kickstarter models - the left
mark on the flywheel (Fig. 7G/H-2) is aligned
with the mark on the stator (Fig. 7G-1).
600cc- and electrical starter models - the
right mark on the flywheel (Fig. 7G/H-3) is
aligned with the mark on the stator (Fig.7G-1).
If the ignition needs to be adjusted, remove the
cover, slightly undo the three screws of the
stator (Fig. 7H-1) and adjust the stator.
Tighten the screws.

ENGINE
18
7
Fig.
7I
Fig.
7J
ATTENTION:
Service more frequently when
riding under hard conditions
7 C
AIRFILTER:
To avoid any engine damages or lack of power
the air filter has to be frequently cleaned or
replaced.
Always use a well-known brand of filter oil after
cleaning. Use an airfilter cleaning solvent of a
well-known brand.
Alwayscheckthesurfaceofthefilterattachment
and the filter basket for any damages.
Always check the surfaces behind the filter for
any loose particles and carefully clean the
surfaces.
Airfilter removal:
Remove the seat (Fig. 7I-1, one quick release
screw on top of the seat).
Remove the wing nut (Fig. 7J-1) holding the
airfilter and airfilter basket (Fig. 7J-2).
Pull the airfilter basket out of the airfilter.
Wash the filter carefully.
Soak the filter in filter oil and squeeze it slightly
for any superfluous oil.
Put the airfilter basket into the filter.
Assembly in reverse order of disassembly.

ENGINE
19
7
Fig.
7L
Fig.
7M
Fig.
7K
ATTENTION:
Service more frequently when
riding under hard conditions
7 D
VALVES:
The clearances between the valve adjustment
screwsand thevalvestemshavetobe checked
after 2 hours of operation when the engine is
brandneworanypartsof thevalves,valveseats
or rockerarms have been changed.
The interval between the checks of the
clearences is afterwards every 10 hours
(MotocrossandDesert models)or20 hours (all
other models).
Valve adjustment:
Remove the fuel tank (see "FUEL & COOLING
- FUEL").
PuttheengineinTDCpositiononcompression
stroke:
Removetheignition cover,installadialindicator
into the spark plug hole (Fig. 7K-1) and turn
theflywheel(wrenchNo.17),clockwise,inorder
to find the upper position of the piston.
Remove the two valve inspection covers (Fig.
7L-1, 2, allen key No. 4) including the gaskets.
Check the clearances of the valves; 0.10 mm
onboththeintakevalvesaswell astheexhaust
valves.Adjust ifnecessary byreleasingthe lock
nut (Fig. 7M-1, wrench No. 10) and then by
adjusting the screw (Fig. 7M-2) into the
adequate clearance.
Refit in the reverse order of disassembly.
Replace the gaskets of the inspection covers if
necessary.

FUEL & COOLING
20
8
ATTENTION:
Service more frequently when
riding under hard conditions
Carburettor setting:
To ensure an easy start of the engine, a high
levelofperformance andareduction of anyrisk
of engine damages, the carburettor has to be
correctly set and adjusted.
The carburettor has an idling screw (Fig.8C-1)
and a mixture screw (Fig.8C-2) that have to be
properly adjusted.In ordertocarry out aproper
adjustmentofthese,the enginehasto bewarm.
With the twistgrip fully closed, turn the idling
screw to a position that makes the engine run
smoothly at idling speed (approximately 1600-
1800 rpm).
Adjust the mixture screw to a position of a
maximum idling speed.
Iftheengine nowruns inatoo high idlingspeed
unscrewthe idling screwuntila satisfying idling
speed is established.
A guideline regarding the mixture screw is 1½-
2½ turns from the bottom position of the screw.
Dependingonthealtitude and thehumidity,the
adjustment may have to be changed whenever
riding under various conditions.
CARBURETTOR:
Always make sure that the throttle (Fig. 8A-1)
returns to a fully closed position.
Always make sure that the twistgrip and cable
move easily.
Alwayskeepthe twistgripandcablewellcleaned
andlubricated.The tubeon topof thecarburettor
(Fig.8A-2)isapointof deteriorationto the cable
andthusavitalpart ofthecableto beinspected.
Always make sure of a 1-2 mm clearance in the
twistgrip. Adjustment is done by removing the
dustprotection (Fig.8B-1),releasingthelocknut
(Fig. 8B-2) and adjusting the adjustment screw
(Fig. 8B-3).
Fig.
8A
Fig.
8B
Fig.
8C
8 A
Always check the intake manifold (Fig. 8C-6)
and the airfilter tube (Fig. 8C-5) for any cracks
and/or leakages and replace if necessary.
Always keep the shaft of the choke lever (Fig.
8C-3) well lubricated.
Always check that the overflow tubes (Fig.8C-4)
on each side of the carburettor are positioned in
a vertical position straight from the outlets and
not crossed nor hanging over the carburettor.
Always ensure that an appropriate fuel is used
(minimum 98 octane) in order to get the most out
ofthe motorcycleand toensure aproper function
of the engine.